Cheese processing method

ABSTRACT

A method and apparatus for processing cheese comprises charging molten process cheese into a mold consisting of a plurality of cardboard lined, open-ended mold cavities oriented in spaced rows and circulating cooling air between and around each row to effect cooling of the cheese to the desired temperature. The rows of columns are defined by pairs of parallel side panels and crossed partitions formed of a rigid material and defining cavities which are elongate and rectangular in cross section. Support members hold the rows of columns in a parallel, spaced apart relation. After cooling, the mold is elevated, allowing the cheese columns covered by cardboard to be discharged from the lower ends of the mold cavities.

BACKGROUND OF THE INVENTION

This invention relates to process cheese and more particularly to amethod and apparatus for molding process cheese into uniform rectangularcolumns.

The production of process cheese involves the heating of natural cheeseand emulsification with alkaline salts. Process cheese is normally soldin three forms. These include slices, five-pound loafs, and bulk sizeswhich can be cut into consumer sizes. The largest size block of processcheese which is normally produced is about 40 pounds and has a volume ofabout 1,000 cubic inches. This is about the maximum size block ofprocess cheese that can be molded and still be sufficiently cooled. Ifprocess cheese is not cooled rapidly enough, it develops a brownishappearance or other discoloration.

The most common practice is to mold process cheese into a formconsisting of corrugated paper with an inner plastic liner. Roundedcorners frequently result because the plastic liner seldom adheresperfectly to the inside of the corrugated paper form. In addition, thecorrugated form has a tendency to bulge due to the heat and the mass ofthe cheese. Also, the surface of the cheese block tends to be relativelyirregular as a result of the fact that as process cheese cools, airbubbles trapped when the cheese is agitated during the manufacturingprocess rise to the surface. Because marketing requires that the cheeseblock be relatively square, these bulges and irregularities, amountingto about 10 percent of the cheese block, must be trimmed. Since onlyabout half of this trim can be reworked into the cheese-making process,substantial wastage results.

SUMMARY OF THE INVENTION

It is an object of the invention to provide a new and improved processand apparatus for molding process cheese.

Another object of the invention is to provide a method and apparatus formolding process cheese wherein the amount of trim wastage issubstantially reduced.

A further object of the invention is to provide a method and apparatusfor molding process cheese wherein wastage is substantially reduced.

Yet another object of the invention is to provide a method and apparatusfor molding process cheese wherein relatively uniform rectangular cheeseblocks can be produced with a minimum of trimming.

A still further object of the invention is to provide a method andapparatus for molding process cheese wherein relatively larger blocks ofcheese can be produced than with existing molding methods.

These and other objects and advantages of the present invention willbecome more apparent from the detailed description thereof taken withthe accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view showing the mold in accordance with thepreferred embodiment of the invention;

FIG. 2 shows a cardboard liner used with the mold shown in FIG. 1; and

FIG. 3 illustrates the cardboard covered process cheese columns afterthe completion of the molding operation.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1 shows the preferred embodiment of the form 10 in which the methodaccording to the invention is practiced. Those skilled in the art willappreciate that modifications in the illustrated form may be madewithout deviating from the inventive concept.

The form 10 includes a plurality of spaced apart rows 11 ofvertically-oriented, rectangular in cross section mold cavities 12.While five rows 11 of mold cavities 12 are illustrated and while threemold cavities 12 in each row are shown, it will be appreciated that anyconvenient number may be employed.

Each row 11 is formed by a pair of identical, rectangular side panels 14and 15 and a plurality of substantially identical partitions 16. As seenin FIG. 1, the partitions 16 all have a length equal to the height ofthe panels 14 and 15 and identical widths. In addition, the partitionsare arranged in parallel, spaced apart relation between the panels 15and 16, with two partitions 16 defining the ends of each row and twointermediate partitions 16 separating the individual mold cavities. Thepartitions 16 are all arranged parallel to each other and maintain thepanels in a parallel, spaced apart relation to define a plurality ofelongate mold cavities 12 which are rectangular in cross section.

The rows 11 of cavities 12 are maintained in a parallel, spaced apartrelation by a plurality of cross members 18 which are affixed to theside edges of the panel members 15 and 16 and upper brace members 20which are fixed to the upper edges of the panel members 15 and 16 andthe intermediate partitions 16. The braces 18 and 20 may be formed ofany conventional structural member which, in the illustrated embodiment,comprises an angle member. Mounted on each of the upper braces 20 is apair of lift hooks 21 whose purpose will be described more fully below.

The panel members 14 and 15 and the partitions 16 may be formed of anysuitable material, such as wood or stainless steel. In the case of wood,the members can be joined with any conventional fasteners or, in thecase of stainless steel, by welding.

FIG. 2 shows the mold liner in accordance with the preferred embodimentof the invention. Preferably, this consists of a food-grade, poly-coatedchipboard box having a removable cover 24 of the same material. Thedimensions of the box 22 and the cover 24 are such that they will beslideably received within the mold cavities 12 with the outer sidesengaging the inner walls of the cavity.

In operation, the form 10 is placed on a pallet 30 of any appropriatetype and size. The cardboard containers 22 are then inserted into eachmold cavity 12, after which molten process cheese, typically at atemperature of about 170° F., is poured into each container 22. It willbe appreciated that the cardboard boxes 22 need be filled only to theheight necessary to achieve the desired sized cheese block. The palletis then elevated and transported to a cold room which is typically at atemperature of about 40° F. Here the cheese slowly cools over a periodof about 48 hours to the temperature of the cold room or about 40° F. Itis desirable that the cheese cool at a relatively slow rate to minimizeshrinkage. The form containing the molded cheese columns and the palletare then removed from the cold room, after which a lifting device, suchas a forklift, is employed for raising the form 11 vertically by meansof the lift hooks 21. The cardboard covered cheese columns 32 dischargefrom the open lower ends of the mold cavities 12 and remain asfree-standing as shown in FIG. 3. The polyurethane coating on the boxesminimizes friction between the outer surface of the boxes and the form10. The cheese columns 32 may then be placed in cold storage ortransported to a cutting area where the outer cardboard boxed 22 areremoved and the cheese cut into blocks of the desired size.

Because the form 11 supports the cheese column during the pouring andcooling steps, each of the cheese columns has relatively planar sidesand square corners. As a result, very little, if any, trimming of theseportions of the columns is required.

In addition, because the columns are oriented vertically during pouringand cooling, all of the dissolved air which discharges from the cheesepasses upwardly through the relatively small upper surface of thecolumn. Therefore, it is only necessary to trim this portion of thecheese columns before packaging. Since the upper portion of the columnrepresents only about one percent of the total cheese volume, only arelatively small portion of the column need be trimmed. Thissubstantially minimizes wastage over prior art methods.

It has been found that in order to achieve the desired cooling rate, noportion of the cheese should be more than three inches from a surfaceexposed to cooling air. It is, therefore, desirable to limit thethickness of the mold cavities to about six inches or less. However,merely by lengthening the mold cavity 10 or increasing its width, theoverall weight of each cheese block can be widely adjusted.

While only a single embodiment of the invention has been illustrated anddescribed, it is not intended to be limited thereby, but only by thescope of the appended claims.

I claim:
 1. A method of processing cheeses including the steps of:providing mold means defining a plurality of rows of spaced apart moldcavities, each mold cavity being vertically oriented, open-ended andrectangular in horizontal cross section, said mold means beingsufficiently rigid to resist bulging under the weight of a column ofcheese disposed therein, inserting into each mold cavity a cardboardliner sized to fit within the cavity and wherein said mold meansprovides support against outward bulging of the cardboard liner, pouringinto each cardboard liner a quantity of process cheese to form a columnof process cheese therein, circulating cooling air along the outside ofeach row of mold cavities and between said rows for cooling said columnsof process cheese to a predetermined temperature, elevating the moldcavity defining means so that the cardboard covered cheese columns aredischarged from the lower end thereof and removing the cardboard linersand cutting the cheese columns to desired lengths.
 2. The method setforth in claim 1 and including the step of limiting the thickness ofeach mold cavity so that no point therein is more than about threeinches from a mold surface exposed to cooling air.
 3. A method ofprocessing cheese including the steps of: providing mold means defininga plurality of rows of spaced apart mold cavities, said mold cavitiesbeing elongate, vertically oriented and open-ended, said mold meansbeing sufficiently rigid to resist bulging under the weight of a columnof cheese disposed therein, inserting into each of a plurality of moldcavities a liner sized to fit within the cavity and wherein said moldmeans provides support against outward bulging of the liner, insertinginto each of a plurality of liners a quantity of process cheese to forma column of process cheese in each, circulating cooling fluid along theoutside of each row of mold cavities and between said rows for coolingsaid columns of process cheese to a predetermine temperature, separatingthe cheese columns from the mold cavity defining means, removing saidliner from said cheese columns and cutting the cheese columns to desiredsized pieces.